U.S. patent application number 11/770281 was filed with the patent office on 2009-01-01 for nano-sized metal and metal oxide particles for more complete fuel combustion.
This patent application is currently assigned to James Kenneth Sanders. Invention is credited to James Kenneth Sanders, Richard Wilson Tock, Duck Joo Yang.
Application Number | 20090000186 11/770281 |
Document ID | / |
Family ID | 40158760 |
Filed Date | 2009-01-01 |
United States Patent
Application |
20090000186 |
Kind Code |
A1 |
Sanders; James Kenneth ; et
al. |
January 1, 2009 |
NANO-SIZED METAL AND METAL OXIDE PARTICLES FOR MORE COMPLETE FUEL
COMBUSTION
Abstract
A fuel composition contains a liquid fuel and nano-sized metal
particles or nano-sized metal oxide particles or combinations
thereof. The nano-sized metal particles and nano-sized metal oxide
particles can be used to either improve combustion or increase
catalytic chemical oxidation of fuel.
Inventors: |
Sanders; James Kenneth;
(Lubbock, TX) ; Tock; Richard Wilson; (Humbolt,
IA) ; Yang; Duck Joo; (Flower Mound, TX) |
Correspondence
Address: |
AMIN, TUROCY & CALVIN, LLP
127 Public Square, 57th Floor, Key Tower
CLEVELAND
OH
44114
US
|
Assignee: |
Sanders; James Kenneth
Lubbock
TX
|
Family ID: |
40158760 |
Appl. No.: |
11/770281 |
Filed: |
June 28, 2007 |
Current U.S.
Class: |
44/321 |
Current CPC
Class: |
C10L 1/12 20130101; C10L
1/10 20130101; C10L 1/1208 20130101; C10L 10/12 20130101; C10L
1/1233 20130101; C10L 10/00 20130101; C10L 10/02 20130101; C10L
10/10 20130101; C10L 1/103 20130101 |
Class at
Publication: |
44/321 |
International
Class: |
C10L 1/12 20060101
C10L001/12 |
Claims
1. A fuel composition comprising: a liquid fuel; and from about
0.01 ppm to about 500 ppm of nano-sized metal particles or the
nano-sized metal oxide particles or combinations thereof, where at
least about 90% by weight of the nano-sized metal particles or the
nano-sized metal oxide particles or combinations thereof have a
size from about 1 nm to about 990 nm.
2. The fuel composition of claim 1, wherein the nano-sized metal
particles or the nano-sized metal oxide particles or combinations
thereof have a surface area from about 50 m.sup.2/g to about 1,000
m.sup.2/g.
3. The fuel composition of claim 1, wherein at least about 90% by
weight of the nano-sized metal particles or the nano-sized metal
oxide particles or combinations thereof have a size from about 1 nm
to about 75 nm.
4. The fuel composition of claim 1, wherein the nano-sized metal
particles or the nano-sized metal oxide particles or combinations
thereof are selected from the group consisting of Group IIa metals,
Group IIa metal oxides, Group IIIa metals, Group IIa metal oxides,
Group IVa metals, Group IVa metal oxides, Group VIII metals, Group
VIII metal oxides, Group Ib metals, Group Ib metal oxides, Group
IIb metals, Group IIb metal oxides, Group IIIb metals, and Group
IIIb metal oxides.
5. The fuel composition of claim 1, wherein the nano-sized metal
particles or the nano-sized metal oxide particles or the
combinations thereof are selected from the group consisting of
magnesium, calcium, strontium, barium, cerium, titanium, zirconium,
iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel,
palladium, platinum, copper, silver, gold, zinc, aluminum, mixed
metal particles thereof, alloy metal particles, calcium oxides,
strontium oxides, barium oxides, cerium oxides, titanium oxides,
zirconium oxides, iron oxides, ruthenium oxides, osmium oxides,
cobalt oxides, rhodium oxides, iridium oxides, nickel oxides,
palladium oxides, platinum oxides, copper oxides, silver oxides,
gold oxides, zinc oxides, aluminum oxides, mixed metal oxide
particles thereof, and mixed metal-metal oxide particles
thereof.
6. The fuel composition of claim 1 comprising from about 0.01 ppm
to about 500 ppm of the nano-sized metal particles or the
nano-sized metal oxide particles or the combinations thereof having
a substantially spherical shape.
7. The fuel composition of claim 1 further comprising from about
0.001% to about 0.5% by weight of a surfactant.
8. The fuel composition of claim 1 having a higher RON, MON, and/or
CN than a RON, MON, and/or CN for a second fuel composition
comprising the liquid fuel but without the nano-sized metal and the
nano-sized metal oxide particles.
9. The fuel composition of claim 1, wherein the liquid fuel is
selected from the group consisting of gasoline, reformulated
gasoline, oxygenated gasoline, diesel, jet fuel, marine fuel,
biodiesel, bioalcohol, alcohol, and kerosene.
10. A method of improving combustion, comprising: providing an
internal combustion engine with a fuel composition comprising a
liquid fuel and from about 0.01 ppm to about 500 ppm of nano-sized
metal particles or nano-sized metal oxide particles or combinations
thereof, where at least about 90% by weight of the nano-sized metal
particles or the nano-sized metal oxide particles or the
combinations thereof have a size from about 1 nm to about 990
nm.
11. The method of claim 10, wherein the nano-sized metal particles
or the nano-sized metal oxide particles or the combinations thereof
have a surface area from about 50 m.sup.2/g to about 1,000
m.sup.2/g.
12. The method of claim 10, wherein the nano-sized metal particles
or the nano-sized metal oxide particles or the combinations thereof
have a surface area from about 100 m.sup.2/g to about 750
m.sup.2/g.
13. The method of claim 10, wherein at least about 90% by weight of
the at least one of the nano-sized metal particles and the
nano-sized metal oxide particles have a size from about 2 nm to
about 250 nm.
14. The method of claim 10, wherein the internal combustion engine
is one of an Otto-cycle engine, a diesel engine, a rotary engine,
and a gas turbine engine.
15. The method of claim 10, wherein improving combustion comprises
at least one of: increasing power output compared to a second fuel
composition comprising the liquid fuel but without the nano-sized
metal or the nano-sized metal oxide particles or combinations
thereof, catalyzing combustion, and increasing surface area where
combustion occurs.
16. A method of increasing catalytic chemical oxidation of a fuel
composition, comprising: providing a fuel composition with a liquid
fuel and from about 0.01 ppm to about 500 ppm of nano-sized metal
particles or nano-sized metal oxide particles or combinations
thereof, where at least about 90% by weight of the at least one of
the nano-sized metal particles and the nano-sized metal oxide
particles have a size from about 1 nm to about 990 nm.
17. The method of claim 16 further comprising at least one of
mixing, stirring, blending, shaking, and sonicating the fuel
composition.
18. The method of claim 16, wherein the nano-sized metal particles
or the nano-sized metal oxide particles or the combinations thereof
are combined with the liquid fuel by combining a fuel additive
composition comprising the nano-sized metal particles and
nano-sized metal oxide particles and a carrier with the liquid
fuel.
19. The method of claim 16, wherein the nano-sized metal particles
or the nano-sized metal oxide particles or the combinations thereof
are selected from the group consisting of Group IIa metals, Group
IIa metal oxides, Group IIa metals, Group IIIa metal oxides, Group
IVa metals, Group IVa metal oxides, Group VII metals, Group VII
metal oxides, Group Ib metals, Group Ib metal oxides, Group IIb
metals, Group IIb metal oxides, Group IIIb metals, and Group IIIb
metal oxides.
20. The method of claim 16, further comprising providing the fuel
composition with a surfactant.
21. A method of making a fuel composition comprising: suspending
from about 0.01 ppm to about 500 ppm of nano-sized metal particles
or nano-sized metal oxide particles or combinations thereof in a
liquid fuel, where at least about 90% by weight of the nano-sized
metal particles or the nano-sized metal oxide particles or
combinations thereof have a size from about 1 nm to about 990
nm.
22. The method of claim 21, wherein the nano-sized metal particles
or the nano-sized metal oxide particles or the combinations thereof
are pre-coated with a surfactant.
23. The method of claim 22, wherein the pre-coated nano-sized metal
particles or nano-sized metal oxide particles or combinations
thereof are prepared by mixing the nano-sized metal particles or
nano-sized metal oxide particles or combinations thereof with a
surfactant dissolved in a solvent followed by drying.
24. The method of claim 23, wherein mixing comprises stirring,
blending, shaking, sonicating, or agitating.
25. The method of claim 23, wherein drying comprises oven drying,
vacuum drying, or spray drying.
Description
TECHNICAL FIELD
[0001] Provided are nano-sized metal particles and metal oxide
particles to facilitate fuel combustion and methods of improving
fuel combustion.
BACKGROUND
[0002] Engine manufacturers continue to seek improved fuel economy
through engine design. Alternative approaches in improving fuel
economy include formulating new fuels and engine oils. Combustion
engines such as automobile engines typically require high octane
gasoline for efficient operation. In the past, lead was added to
gasoline to increase the octane number. Due to health and
environmental concerns, however, lead was removed from gasoline.
Lead can also poison a catalytic converter dramatically reducing
its lifetime. Oxygenates, such as methyl-t-butyl ether (MTBE) and
ethanol, may be added to gasoline to increase the octane number.
While generally less toxic than lead, some suggest MTBE can be
linked to ground water contamination. There is also a desire by
some to reduce some of the high octane components normally present
in gasoline, such as benzene, aromatics, and olefins.
SUMMARY
[0003] The following presents a simplified summary of the invention
in order to provide a basic understanding of some aspects of the
invention. This summary is not an extensive overview of the
invention. It is intended to neither identify key or critical
elements of the invention nor delineate the scope of the invention.
Rather, the sole purpose of this summary is to present some
concepts of the invention in a simplified form as a prelude to the
more detailed description that is presented hereinafter.
[0004] The subject invention provides nano-sized metal particles
and nano-sized metal oxide particles that can be used to improve
combustion, decrease harmful exhaust emissions, and increase
catalytic chemical oxidation of fuel.
[0005] One aspect of the invention relates to a fuel composition
containing a liquid fuel and at least one of nano-sized metal
particles, or nano-sized metal oxide particles, or combination
thereof. Another aspect of the invention relates to a fuel additive
composition containing a carrier/organic solvent and at least one
of nano-sized metal particles, or nano-sized metal oxide particles
or combination thereof. Other aspects of the invention include
methods of making fuel compositions, methods of improving
combustion, and methods of increasing catalytic chemical oxidation
of a fuel composition.
[0006] To the accomplishment of the foregoing and related ends, the
invention comprises the features hereinafter fully described and
particularly pointed out in the claims. The following description
and the annexed drawings set forth in detail certain illustrative
aspects and implementations of the invention. These are indicative,
however, of but a few of the various ways in which the principles
of the invention may be employed. Other objects, advantages and
novel features of the invention will become apparent from the
following detailed description of the invention when considered in
conjunction with the drawings.
BRIEF SUMMARY OF THE DRAWINGS
[0007] FIG. 1 illustrates a bar graph demonstrating the hydrocarbon
emissions from various fuels from various engines.
[0008] FIG. 2 illustrates a bar graph demonstrating the octane
ratings of various fuel compositions.
DETAILED DESCRIPTION
[0009] Nano-sized metal particles and/or nano-sized metal oxide
particles are combined with fuel to improve fuel combustion. The
nano-sized metal particles may be present in a fuel additive
composition which is combined (that is, either suspended or
dispersed) with fuel to make a fuel composition, or present in a
fuel composition.
[0010] While not wishing to be bound by any theory, when nano-sized
metal particles are present in a liquid fuel composition which is
oxidized in the combustion process, an added energy source is
provided. The nano-sized metal particles may increase the catalytic
chemical oxidation or combustion of hydrocarbon based fuels.
Consequently, an increase in engine power is achieved. Still not
wishing to be bound by any theory, it is believed that nano-sized
metal or metal oxide particles or combinations thereof present in a
liquid fuel composition provide a catalytic surface capable of
supplying oxygen to the combustion process during transient
reducing atmospheric episodes generated by the combustion process.
Since the combustion process is more complete, an environmentally
friendly internal combustion engine fuel is provided.
[0011] The nano-sized metal or metal oxide particles or combination
thereof may also be involved in other reactions that improve the
combustion. For example, the nano-sized metal oxide particles can
sequester low levels of water which otherwise can contaminate
fuels, especially those fuels containing oxygenates such as
alcohol. It is believed that this sequestration with the presence
of ethanol provides an added benefit by decreasing the sensitivity
or difference between the RON and the MON levels for ethanol. The
decrease in sensitivity increases the fuels performance when the
engine is under load and can give rise to an increased octane
rating for the fuel. The nano-sized metal or metal oxide particles
may function to form a coating on metal parts within the internal
combustion engine, thereby not only adding lubricity but also
preventing carbon deposition on the internal engine parts. This
reduces engine maintenance.
[0012] Nano-sized metal or metal oxide particles or combination
thereof are added to hydrocarbon based fuels to increase power
output during combustion. Combustion processes (oxidation of
hydrocarbon fuels) can occur an order of magnitude faster by a
substantially heterogeneous reaction on solid catalytic surfaces
(provided by the nano-sized metal and metal oxide particles) than
do the same oxidation processes in homogeneous gas phase reactions
without the metal and metal oxide particles. The invention thus
provides nano sized solid catalyst having a significantly increased
surface area needed for more complete combustion.
[0013] The nano-sized metal particles and metal oxide particles
have a size suitable to catalyze the combustion reaction of fuels,
yet have 1) an ability to pass through fuel filters and 2) at least
substantially combust themselves, or sublime, or otherwise be
consumed so that particulate emissions are minimized and/or
eliminated. In one embodiment, the nano-sized metal particles and
metal oxide particles have a size where at least about 90% by
weight of the particles have a size from about 1 nm to about 990
nm. In this connection, size refers to average cross-section of a
particle, such as diameter. In another embodiment, the nano-sized
metal particles and metal oxide particles have a size where at
least about 90% by weight of the particles have a size from about 1
nm to about 75 nm. In yet embodiment, the nano-sized metal
particles and metal oxide particles have a size where at least
about 90% by weight of the particles have a size from about 1.5 nm
to about 40 nm. In still yet embodiment, the nano-sized metal
particles and metal oxide particles have a size where at least
about 90% by weight of the particles have a size from about 2 nm to
about 20 nm. In still yet embodiment, the nano-sized metal
particles and metal oxide particles have a size where at least
about 90% by weight of the particles have a size from about 1 nm to
about 10 nm. In another embodiment, about 100% by weight of the
particles have any of the sizes described above, including a size
of less than about 20 nm.
[0014] The nano-sized metal particles and metal oxide particles
have a surface area suitable to catalyze the combustion reaction of
fuels and to increase the rate of combustion compared to using the
same amount of catalyst in bulk form. Increased surface area is
often better achieved via small sized particles rather than
particles with high porosity. In one embodiment, the nano-sized
metal particles and metal oxide particles have a surface area from
about 50 m.sup.2/g to about 1,000 m.sup.2/g. In another embodiment,
the nano-sized metal particles and metal oxide particles have a
surface area from about 100 m.sup.2/g to about 750 m.sup.2/g. In
yet another embodiment, the nano-sized metal particles and metal
oxide particles have a surface area from about 150 m.sup.2/g to
about 600 m.sup.2/g.
[0015] The nano-sized metal particles and metal oxide particles
have a morphology suitable to catalyze the combustion reaction of
fuels, increase the rate of combustion compared to using the same
amount of catalyst in bulk form, yet have an ability to pass
through fuel filters. Examples of the one or more morphologies the
nano-sized metal particles and metal oxide particles may have
include, spherical, substantially spherical, oval, popcorn-like,
plate-like, cubic, pyramidal, cylindrical, and the like. The
nano-sized metal particles and metal oxide particles may be
crystalline, partially crystalline, or amorphous.
[0016] The nano-sized metal particles and metal oxide particles
contain any material suitable to catalyze the combustion reaction
of fuels. General examples of materials of metal particles and/or
metal oxide particles include one or more of the following
(referring to Groups of the Periodic Table of Elements): Group IIa
metals, Group IIa metal oxides, Group IIIa metals, Group IIIa metal
oxides, Group IVa metals, Group IVa metal oxides, Group VIII
metals, Group VIII metal oxides, Group Ib metals, Group Ib metal
oxides, Group IIb metals, Group IIb metal oxides, Group IIIb
metals, and Group IIIb metal oxides. More specific examples of
materials of metal particles and/or metal oxide particles include
one or more of the following: magnesium, calcium, strontium,
barium, cerium, titanium, zirconium, iron, ruthenium, osmium,
cobalt, rhodium, iridium, nickel, palladium, platinum, copper,
silver, gold, zinc, aluminum, mixed metal particles, alloy metal
particles, calcium oxides, strontium oxides, barium oxides, cerium
oxides, titanium oxides, zirconium oxides, iron oxides, ruthenium
oxides, osmium oxides, cobalt oxides, rhodium oxides, iridium
oxides, nickel oxides, palladium oxides, platinum oxides, copper
oxides, silver oxides, gold oxides, zinc oxides, aluminum oxides,
mixed metal oxide particles, and mixed metal-metal oxide
particles.
[0017] In one embodiment, the nano-sized metal particles and/or
metal oxide particles do not contain health hazardous and
environmentally non-friendly (by current or future standards)
metals and metal oxides. For example, in one embodiment, the
nano-sized metal particles and/or metal oxide particles do not
contain lead and/or lead oxide.
[0018] In one embodiment, the nano-sized metal particles contains
mixed metal particles and/or mixed metal oxide particles containing
at least two metals/metal oxides, at least three metals/metal
oxides, or at least four metals/ metal oxides. Examples of mixed
metal particles and mixed metal oxide particles include one or more
of the following: aluminum-magnesium, aluminum-iron, aluminum-zinc,
zinc-magnesium, zinc-magnesium-iron, calcium-magnesium,
calcium-magnesium-zinc, calcium-magnesium-iron, nickel-magnesium,
aluminum-nickel, nickel-magnesium-aluminum, aluminum-cerium,
aluminum-magnesium oxides, aluminum-iron oxides, aluminum-zinc
oxides, zinc-magnesium oxides, zinc-magnesium-iron oxides,
calcium-magnesium oxides, calcium-magnesium-zinc oxides,
calcium-magnesium-iron oxides, nickel-magnesium oxides,
aluminum-nickel oxides, nickel-magnesium-aluminum oxides,
aluminum-cerium oxides, and the like.
[0019] Many of the nano-sized metal particles and/or metal oxide
particles are commercially available from a number of sources
including Sigma-Aldrich Inc. Alternatively, metal oxides can be
made by converting a metal salt to its corresponding metal or metal
oxide by methods known in the art. The conversion can take place in
an inert atmosphere or in air via heating, such as calcining in an
inert or atmospheric environment or heating in solution.
[0020] In one embodiment, a metal salt is dissolved in a liquid and
subjected to ultrasound irradiation followed by its conversion to
metal or metal oxide. Metal salts include metal carboxylates, metal
halides, and metal acetylacetonates. That is, metal carboxylates,
metal halides, and metal acetylacetonates may be used to make metal
oxides. Metal carboxylates include metal acetates, metal
ethylhexanoates, metal gluconates, metal oxalates, metal
propionates, metal pantothenates, metal cyclohexanebutyrates, metal
bis(ammonium lacto)dihydroxides, metal citrates, and metal
methacrylates. Specific examples of metal carboxylates include
aluminum lactate, calcium acetate, calcium ethylhexanoate, calcium
gluconate, calcium oxalate, calcium propionate, calcium
pantothenate, calcium cyclohexanebutyrate, cerium acetate, cerium
oxalate, cesium acetate, cesium formate, iron acetate, iron
citrate, iron oxalate, magnesium acetate, magnesium
methylcarbonate, magnesium gluconate, nickel acetate, nickel
ethylhexanoate, nickel octanoate, tin acetate, tin oxalate,
titanium bis(ammonium lacto)dihydroxide, zinc acetate, zinc
methacrylate, zinc stearate, zinc cyclohexanebutyrate, zirconium
acetate, zirconium citrate.
[0021] Two or more metal salts may be used to form mixed metal
oxides. Mixed metal oxides contain at least two different metal
oxides. Mixed metal oxides contain at least three different metal
oxides. Alternatively, mixed metal oxides contain at least four
different metal oxides.
[0022] Any suitable liquid can be used to convert a metal salt such
as a metal carboxylate to a metal oxide. Examples of liquids
include water and organic solvents such as alcohols, ethers,
esters, ketones, alkanes, aromatics, and the like. When using an
absolute alcohol such as absolute ethanol as the liquid, the
alcohol complexes with water that may be liberated during the
conversion process.
[0023] Methods of making metal particles and metal oxide particles
are known in the art and described in U.S. Pat. No. 5,039,509; U.S.
Pat. No. 5,106,608; U.S. Pat. No. 5,654,456; U.S. Pat. No.
6,179,897 (combining metal with graphite, heating to form an
intermediate metal carbide, applying apply more heat to decompose
the metal carbide and release the metal as a vapor, then oxidizing
to form a pure metal oxide powder); PCT Publication Number
WO/2007/000014; all of which are hereby incorporated by
reference.
[0024] The nano-sized metal particles and/or metal oxide particles
(or the fuel compositions or fuel additive compositions) may
contain or have coated thereon one or more surfactants. Surfactants
can facilitate one or more of suspending the particles within the
fuel composition, preventing agglomeration, promoting compatibility
between the particles and liquid fuel, and the like. Any suitable
surfactant can be employed including ionic surfactants, anionic
surfactants, cationic surfactants, amphoteric surfactants, and
nonionic surfactants. Surfactants are known in the art, and many of
these surfactants are described in McCutcheon's "Volume I:
Emulsifiers and Detergents", 1995, North American Edition,
published by McCutcheon's Division MCP Publishing Corp., Glen Rock,
N.J., and in particular, pp. 1-232 which describes a number of
anionic, cationic, nonionic and amphoteric surfactants and is
hereby incorporated by reference for the disclosure in this
regard.
[0025] Examples of anionic (typically based on sulfate, sulfonate
or carboxylate anions) surfactants include sodium dodecyl sulfate
(SDS), ammonium lauryl sulfate, and other alkyl sulfate salts,
sodium laureth sulfate, also known as sodium lauryl ether sulfate
(SLES), alkyl benzene sulfonate, soaps, or fatty acid salts (see
acid salts).
[0026] Examples of cationic (typically based on quaternary ammonium
cations) surfactants include cetyl trimethylammonium bromide (CTAB)
a.k.a. hexadecyl trimethyl ammonium bromide, and other
alkyltrimethylammonium salts, cetylpyridinium chloride (CPC),
polyethoxylated tallow amine (POEA), benzalkonium chloride (BAC),
and benzethonium chloride (BZT).
[0027] Examples of zwitterionic surfactants or amphoteric
surfactants include dodecyl betaine, dodecyl dimethylamine oxide,
cocamidopropyl betaine, and coco ampho glycinate.
[0028] Examples of nonionic surfactants include alkyl poly(ethylene
oxide); alkyl polyglucosides, such as octyl glucoside, and decyl
maltoside; fatty alcohols such as cetyl alcohol and oleyl alcohol;
cocamide MEA, cocamide DEA, and cocamide TEA.
[0029] In one embodiment, the fuel composition contains from about
0.001% to about 1% by weight of one or more surfactants. In another
embodiment, the fuel composition contains from about 0.01% to about
0.1% by weight of one or more surfactants.
[0030] The nano-sized metal particles and metal oxide particles can
be at least partially suspended, but typically suspended, in a
liquid fuel composition in any suitable manner. The relatively
small size of the nano-size particles contributes to the inherent
ability to remain suspended over a longer period of time compared
to relatively larger particles (larger than a micron), even though
the density and/or specific gravity of the nano-size particles may
be several times greater than the corresponding density and/or
specific gravity of the liquid fuel. The longer suspension times
mean that the liquid fuel containing the nano-size particles
entering the engine over time contains a more uniform and/or
consistent dispersion of the nano-size particles.
[0031] A suspension contains the nano-sized metal particles and/or
metal oxide particles and a carrier fluid that is compatible with
the fuel. For example, when the nanoparticles are made in the
alcohol solution, or when toluene or xylenes are used as a carrier
fluid, the resulting suspension can be added directly to pump
gasoline. Analogously, for diesel fuels, another carrier fluid
which is more of a cetane enhancer can be employed. The use of one
or more suitable surfactants with a carrier fluid that is
compatible with the fuel can enhance the suspension of the
nanoparticles.
[0032] The nano-sized metal particles and metal oxide particles can
be in dry powder form. The powdered form may be prepared by spray
drying a suspension of the nano-sized metal particles and metal
oxide particles. An inert gas such as nitrogen can be used to spray
dry the particles. The coated powder can then be added to fuel or
an engine as a powder or made into a fuel compatible paste. The
powder can be directly added into the air intake of an engine
instead of adding the powder to the fuel.
[0033] The uniformity of dispersion and/or duration of suspension
can also be established or facilitated by the use of one or more
suitable surfactants. Examples of such surfactants include
amphoteric surfactants, ionic surfactants, and non-ionic
surfactants. In one embodiment, however, the surfactant does not
contain sulfur atoms. In another embodiment, the surfactant does
not contain halide atoms. If employed, the surfactant can be added
to the liquid fuel composition before, during, or after the
nano-size particles are combined with the fuel. Alternatively, the
nano-size particles may be contacted or coated with the surfactant
before addition to the fuel. The powdered form can be prepared by
spray drying a suspension of the nano-sized metal particles or
metal oxide particles containing one or more suitable surfactants.
Alternatively, oven drying or vacuum drying may be employed to form
the surfactant coated particles. To be safe during spray drying, an
inert gas such as nitrogen can be used to spray dry the particles
with surfactant. The powder coated with surfactant can then be
added to fuel.
[0034] The uniformity of dispersion and/or duration of suspension
can also be established or facilitated by mixing, stirring,
blending, shaking, sonicating, or otherwise agitating the liquid
fuel composition containing the nano-size particles.
[0035] The liquid fuel composition contains a suitable amount of at
least partially suspended nano-sized metal particles and/or metal
oxide particles to catalyze the combustion reaction of fuels. In
one embodiment, the liquid fuel composition contains a liquid fuel
and from about 0.01 ppm to about 500 ppm of suspended nano-sized
metal particles and/or metal oxide particles. In another
embodiment, the liquid fuel composition contains a liquid fuel and
from about 0.05 ppm to about 250 ppm of suspended nano-sized metal
particles and/or metal oxide particles. In yet another embodiment,
the liquid fuel composition contains a liquid fuel and from about
0.1 ppm to about 100 ppm of suspended nano-sized metal particles
and/or metal oxide particles. In still yet another embodiment, the
liquid fuel composition contains a liquid fuel and from about 1 ppm
to about 75 ppm of suspended nano-sized metal particles and/or
metal oxide particles.
[0036] A fuel additive composition provides an efficient means to
store and transport the nano-sized metal particles and/or metal
oxide particles prior to the addition with a liquid fuel. In one
embodiment, the fuel additive composition is simply a dry powder
coated with one or more suitable surfactants. Or in another
embodiment, no surfactant is used. In another embodiment, the fuel
additive composition is a paste containing from about 10% by weight
to about 95% by weight of the nano-sized metal particles and/or
metal oxide particles and from about 5% by weight to about 90% by
weight of a fuel compatible organic solvent and from about 5% by
weight to about 10% by weight of one or more suitable surfactants.
In yet embodiment, the fuel additive composition is a combination
of a carrier liquid and the nano-sized metal particles and/or metal
oxide particles and one or more suitable surfactants.
[0037] The fuel composition or fuel additive composition may
optionally contain a bicyclic aromatic compound. Examples of
bicyclic aromatic compounds include naphthalene, substituted
naphthalenes, biphenyl compounds, biphenyl compound derivatives,
and mixtures thereof. In one embodiment, the fuel composition
contains from about 0.01 ppm to about 1000 ppm while the fuel
additive composition contains from about 0.1% by weight to about
10% by weight of one or more bicyclic aromatic compounds. In
another embodiment, the fuel composition contains from about 0.1
ppm to about 500 ppm while the fuel additive composition contains
from about 0.5% by weight to about 5% by weight of one or more
bicyclic aromatic compounds.
[0038] The nano-sized metal and/or metal oxide particles and the
optional bicyclic aromatic compound in the fuel additive
composition can be dispersed in a carrier liquid to form a fuel
additive composition. A carrier liquid has a flash point of at
least 100.degree. F. and an auto-ignition temperature of at least
400.degree. F. or is a C1-C3 alcohol. Examples of carrier liquids
include one or more of toluene, xylenes, kerosene and C1-C3
monohydric, dihydric or polyhydric aliphatic alcohols. Examples of
aliphatic alcohols include methanol, ethanol, n-propanol, isopropyl
alcohol, ethylene glycol, propylene glycol, and the like. In one
embodiment, the fuel additive composition contains at least 90% by
weight of a carrier liquid and no more than 10% by weight of the
nano-sized metal and/or metal oxide particles.
[0039] Some fuels and fuel additives contain relatively large or
small quantities of ketones, such as acetone, or ethers, such MTBE.
A relatively large or small quantity of a ketone or ether is not
necessary in the fuel compositions and fuel additive compositions.
In one embodiment, a relatively large quantity (more than 5% by
volume) of a ketone or ether is not present in the fuel
compositions and/or fuel additive compositions because ketones and
ethers may decrease the solubility of the nano-sized metal and/or
metal oxide particles and undesirably reduce the flash point of the
resultant fuel composition.
[0040] Fuel compositions are made by combining the nano-sized metal
and/or metal oxide particles and a liquid fuel. Examples of liquid
fuels include hydrocarbon fuels such as gasoline, reformulated
gasoline, diesel, jet fuel, marine fuel, kerosene, biofuels such as
biodiesel, bioalcohols such as bioethanol, and the like. Gasoline
contains one or more of the following components that may, by
themselves, constitute liquid fuel: straight-run products,
reformate, cracked gasoline, high octant stock, isomerate,
polymerization stock, alkylate stock, hydrotreated feedstocks,
desulfurization feedstocks, alcohol, and the like.
[0041] In one embodiment, the fuel additive composition or the
nano-sized metal and/or metal oxide particles coated with or
without one or more suitable surfactants is/are added to the liquid
fuel in an amount sufficient to provide decrease of at least about
10% in hydrocarbon and/or carbon monoxide emissions from the
exhaust system as compared to the corresponding emissions from use
of the liquid fuel without inclusion of the nano-sized metal and/or
metal oxide particles. In another embodiment, the fuel additive
composition or the nano-sized metal and/or metal oxide particles
coated with or without one or more suitable surfactants is/are
added to the liquid fuel in an amount sufficient to provide
decrease of at least about 25% in hydrocarbon and/or carbon
monoxide and/or nitrogen oxides emissions from the exhaust system
as compared to the corresponding emissions from use of the liquid
fuel without inclusion of the nano-sized metal and/or metal oxide
particles.
[0042] In one embodiment, the fuel additive composition or the
nano-sized metal and/or metal oxide particles coated with or
without one or more suitable surfactants is/are added to the liquid
fuel in an amount sufficient to provide a decrease of at least 5%
in the amount of the liquid fuel consumed by the internal
combustion engine when compared with the corresponding amount of
liquid fuel consumed by the engine when the nano-sized metal and/or
metal oxide particles are not included. In another embodiment, the
fuel additive composition or the nano-sized metal and/or metal
oxide particles is/are added to the liquid fuel in an amount
sufficient to provide a decrease of at least 10% in the amount of
the liquid fuel consumed by the internal combustion engine when
compared with the corresponding amount of liquid fuel consumed by
the engine when the nano-sized metal and/or metal oxide particles
are not included.
[0043] The quality of a fuel such as gasoline can be determined by
octane. Octane is measured relative to a mixture of isooctane
(2,2,4-trimethylpentane, an isomer of octane) and n-heptane. For
example, an 87-octane gasoline has the same octane rating as a
mixture of 87 vol-% isooctane and 13 vol-% n-heptane. A low octane
rating is undesirable in a gasoline engine. The most common type of
octane rating worldwide is the Research Octane Number (RON). RON is
determined by running the fuel through a specific test engine with
a variable compression ratio under controlled conditions, and
comparing these results with those for mixtures of isooctane and
n-heptane. In this connection, RON can be determined using the
procedure set forth in ASTM D 2699, which is hereby incorporated by
reference in its entirety. Another type of octane rating, called
Motor Octane Number (MON), which is in some instances a better
measure of how the fuel behaves when under load. MON testing uses a
similar test engine to that used in RON testing, but with a
preheated fuel mixture, a higher engine speed, and variable
ignition timing to further stress the fuel's knock resistance.
Cetane number or CN a measure of the combustion quality of diesel
fuel under compression, one measure of fuel quality. CN is actually
a measure of a diesel fuel's ignition delay; the time period
between the start of injection and start of combustion (ignition)
of the fuel.
[0044] In one embodiment, a fuel composition containing a liquid
fuel and the nano-sized metal and/or metal oxide particles has a
higher RON, MON, and/or CN than a RON, MON, and/or CN for a fuel
composition with the same ingredients except without the nano-sized
metal and/or metal oxide particles. In another embodiment, a fuel
composition containing a liquid fuel and the nano-sized metal
and/or metal oxide particles can have less than about 5% higher
RON, MON, and/or CN than a RON, MON, and/or CN for a fuel
composition with the same ingredients except without the nano-sized
metal and/or metal oxide particles. In yet another embodiment, a
fuel composition containing a liquid fuel and the nano-sized metal
and/or metal oxide particles has can have less than 10% higher RON,
MON, and/or CN than a RON, MON, and/or CN for a fuel composition
with the same ingredients except without the nano-sized metal
and/or metal oxide particles.
[0045] The fuel composition can be effectively used in both
fuel-injected and non fuel-injected engines. The fuel composition
can be effectively used in two-stroke engines, four-stroke engines,
and vehicle engines such as automobile engines, motorcycle engines,
jet engines, marine engines, truck/bus engines, and the like. The
fuel composition can be effectively used in any type of internal
combustion engine including an Otto-cycle engine, a diesel engine,
a rotary engine, and a gas turbine engine. The fuel composition can
be effectively used in an intermittent internal combustion engine
or a continuous internal combustion engine.
[0046] The fuel composition can supply to the fuel chamber the
liquid fuel and the nano-sized metal and/or metal oxide particles
as a mixture, or the liquid fuel and the nano-sized metal and/or
metal oxide particles can be supplied to the fuel chamber
separately.
[0047] The fuel compositions are tailored to reduce the percentages
of hydrocarbons, carbon monoxide, nitrogen oxides, and molecular
oxygen in motor vehicle exhaust emissions. Use of the fuel
compositions may also result in a desirable increase in the
percentage of carbon dioxide in combustion exhaust emissions. Thus,
the fuel compositions, when used to fuel internal combustion
engines, lead to efficient operation and the resultant emissions
meet or exceed E.P.A. standards. The fuel compositions are also
tailored to have more effective combustion thereby reducing little
or less deposition of carbon residue in the internal chamber of the
combustion engine.
[0048] The following examples illustrate the subject invention.
Unless otherwise indicated in the following examples and elsewhere
in the specification and claims, all parts and percentages are by
weight, all temperatures are in degrees Centigrade, and pressure is
at or near atmospheric pressure.
[0049] Table 1 reports hydrocarbon emissions in parts per million
(ppm) from three different engines at idle and at 2000 rpm using a
fuel without the nano-sized metal and/or metal oxide particles and
a fuel with the nano-sized metal and/or metal oxide particles. The
base fuel is regular unleaded gasoline having an octane rating of
87. The nano-sized metal and/or metal oxide particles are present
at a level of about 50 ppm and are zinc oxide particles having a
size from 1 nm to 20 nm. Engine 1 is a year 2002 Ford F-150 pick-up
V-8; engine 2 is a year 2000 Dodge Ram pick-up V-8; and engine 3 is
a 1999 Audi A8 V-8. Hydrocarbon emissions are measured using a five
gas analyzer with a tailpipe probe (Model 5002 Exhaust Gas Analyzer
made by Emission Systems Inc.).
TABLE-US-00001 TABLE 1 Engine idle w/o cat idle w cat 2000 rpm w/o
cat 2000 rpm w cat 1 10 3 8 1 2 69 6 8 2 3 4 1 8 2
[0050] FIG. 1 is a bar graph for hydrocarbon readings to facilitate
visual comparisons of emissions reported in Table 1. On the bar
graph of FIG. 1, the first set of bars (idle w/o cat) shows the
hydrocarbon emissions from three engines at idle using a fuel
without the nano-sized metal and/or metal oxide particles. The
second set of bars (idle w cat) shows hydrocarbon emissions from
the same three engines at idle using a fuel with the nano-sized
metal and/or metal oxide particles. The final two sets of bars
(2000 rpm w/o cat and 2000 rpm w cat) shows the hydrocarbon
emissions either without or with the nano-sized metal and/or metal
oxide particles from the same three engines, but with the engine
turning at 2000 rpm (a typical turn rate for highway travel). For
both idle and cruising engine turning rates, the reduction in
hydrocarbon emissions is substantial.
[0051] Table 2 reports nitrogen oxide (NOx) emissions in parts per
million (ppm) from two different engines at idle and at 2000 rpm
using a fuel without the nano-sized metal and/or metal oxide
particles and a fuel with the nano-sized metal and/or metal oxide
particles. For both idle and cruising engine turning rates, the
reduction in nitrogen oxide emissions is substantial. The base fuel
is regular unleaded gasoline having an octane rating of 87. The
nano-sized metal and/or metal oxide particles are present at a
level of about 50 ppm and are zinc oxide particles having a size
from 1 nm to 20 nm. Engine 1 is a year 2002 Ford F-150 pick-up V-8
and engine 3 is a 1999 Audi A8 V-8. Nitrogen oxide emissions are
measured using a five gas analyzer with a tailpipe probe (Model
5002 Exhaust Gas Analyzer made by Emission Systems Inc.).
TABLE-US-00002 TABLE 2 Engine idle w/o cat idle w cat 2000 rpm w/o
cat 2000 rpm w cat 1 10 1 207 31 3 3 0 37 2
[0052] Table 3 reports carbon dioxide emissions in parts per
million (ppm) from three different engines at idle and at 2000 rpm
using a fuel without the nano-sized metal and/or metal oxide
particles and a fuel with the nano-sized metal and/or metal oxide
particles. The base fuel is regular unleaded gasoline having an
octane rating of 87. The nano-sized metal and/or metal oxide
particles are present at a level of about 50 ppm and are zinc oxide
particles having a size from 1 nm to 20 nm. Engine 1 is a year 2002
Ford F-150 pick-up V-8 and engine 2 is a year 2000 Dodge Ram
pick-up V-8. Carbon dioxide emissions are measured using a five gas
analyzer with a tailpipe probe (Model 5002 Exhaust Gas Analyzer
made by Emission Systems Inc.).
TABLE-US-00003 TABLE 3 Engine idle w/o cat idle w cat 2000 rpm w/o
cat 2000 rpm w cat 1 13.8 13.7 17.7 15 2 14.3 14.7 14.9 14.8
[0053] Table 4 reports octane ratings from five different fuel
compositions; one without the nano-sized metal and/or metal oxide
particles additive and four with varying amounts of the nano-sized
metal and/or metal oxide particles additive. Each of the five
different fuel compositions contains Murphy's USA regular unleaded
fuel having an octane rating of 87 with or without an additive. The
additive is a different amount of 1 nm to 20 nm zinc oxide
particles. The octane number is measured using an IR scanner (Model
ZX-101XL portable octane and fuel analyzer made by Zeltex
Inc.).
TABLE-US-00004 TABLE 4 Fuel Octane Reading without additive 87.1
with 50 ppm additive 87.8 with 100 ppm additive 88.2 with 150 ppm
additive 88.6 with 200 ppm additive 88.8
FIG. 2 is a bar graph for octane readings to facilitate visual
comparisons of the fuel compositions reported in Table 4. On the
bar graph of FIG. 2, the first bar shows the octane reading from a
fuel composition without the nano-sized metal and/or metal oxide
particles while the second to fifth bars show fuel compositions
with varying amounts of the nano-sized metal and/or metal oxide
particles. All of the fuel compositions with varying amounts of the
nano-sized metal and/or metal oxide particles have higher octane
readings than the fuel composition without the nano-sized metal
and/or metal oxide particles.
[0054] Table 5 illustrates that NOx emissions from diesel fuel with
catalyst were reduced from 125 ppm level to 58 ppm level:
approximately a 53% reduction. Each of the two different diesel
fuel compositions contains Phillips's USA diesel fuel with or
without an additive. The additive is 1 nm to 20 nm zinc oxide
particles. Nitrogen oxide emissions are measured using a five gas
analyzer with a tailpipe probe (Model 5002 Exhaust Gas Analyzer
made by Emission Systems Inc.).
TABLE-US-00005 TABLE 5 NOx Reduction Test Results using Diesel Fuel
with/without catalyst NOx (ppm) Engine Speed: Idle 2,000 rpm 1)
Diesel w/o catalyst 264 125 2) Diesel w/catalyst 257 58
[0055] The data were calculated from averaged where multiple
readings were taken at two engine speeds: 1) Idle and 2) 2,000 rpm.
As shown in Table 5, a two different fuel compositions were used;
1) diesel fuel only and 2) diesel with catalyst. These two fuels
were run sequentially with an initial pump diesel base line
followed by testing with diesel/catalyst.
[0056] With respect to any figure or numerical range for a given
characteristic, a figure or a parameter from one range may be
combined with another figure or a parameter from a different range
for the same characteristic to generate a numerical range.
[0057] While the invention has been explained in relation to
certain embodiments, it is to be understood that various
modifications thereof will become apparent to those skilled in the
art upon reading the specification. Therefore, it is to be
understood that the invention disclosed herein is intended to cover
such modifications as fall within the scope of the appended
claims.
* * * * *